Tufting

ABSTRACT

In order to maintain pattern register between moving yarns having dyestuffs applied thereto at intervals therealong during the transverse rearrangement of such yarns, as, say, to give a pattern repeat, the yarns are all caused to move through a like distance as measured in the longitudinal direction of the yarn, during the rearrangement by providing a guide tube for each yarn through which the yarn passes, the said tubes all being of constant length and each serving to transfer a respective yarn from an initial position transversely of a yarn sheet or sheets issuing from a dyeing means to a final position transversely of a yarn sheet or sheets proceeding to a tufting machine or other combining means.

United States Patent Inventors Robert Spedding 3,395,432 8/l968 Hasleret al 112/79 X ig Blackburn; 3,447,215 6/1969 Tillotson 112/79 x WilhamSandford 11992119, 3,396,687 8/1968 Nowicki 112/790 Blmfkbumi RaymondV1919! Evans, 3,415,209 12/1968 121115011 m1. 1 12/79 Fenlscowles,Blackburn, all of England [21] Appl. 771,936 Primary Examiner-JordanFranklin [22] Filed Oct 30, 1968 Assistant Examiner-Geo. V. Larkin [45]Patented No 30 1971 Attorneys-Marshall J. Breen, Chester A. Williams andJulian 731 Assignee Singer-Cobble Limited Blackburn, England [32]Priority Oct. 31,1967 [33] United Kingdom [3|] 49,362/67 TUNINGABSTRACT: In order to maintain pattern register between moving yarnshavlng dyestuffs applied thereto at mtervals 7 Claims, 2 Drawing Figs.

therealong during the transverse rearrangement of such yarns, [52] US.Cl 112/79 A as, say, to give a pattern repeat, the yarns are all causedto [5 l] lnt. CL ..D05c 15/00, move through a like distance as measuredin the longitudinal DOSc 15/18 direction of the yarn, during therearrangement by providing a [50] Field of Search ll2/79, guide tube foreach yarn through which the yarn passes. the 79.5, 79.6, 118 said tubesall being of constant length and each serving to transfer a respectiveyarn from an initial position transversely [56] Reierences Cited of ayarn sheet or sheets issuing from a dyeing means to a final UNITEDSTATES PATENTS position transversely of a yarn sheet or sheetsproceeding to a 1,990,907 2 1935 Kellogg 1 12/79 tuftins machine orother combining means- PATENTEnunv 30 I97! 3, 623 ,440

sum 1 or =3 23 13 13 fly INVENTORS= Robert Spedding, William S. Hosler,and Raymond V. Evans BY KW ATTORNEY PATENTEmmv 30 Ian sum 2 BF 2INVENTORS:

ATTORNEY TUFTING This invention concerns the production of tuftedfabrics, and has more particular reference to a method of and a meansfor maintaining pattern register between the individual yarns of amultiplicity thereof passing from a dyeing means to a tufting machine.

In the production of a tufted fabric having a pattern in the pile due toa variation in pile height, which pattern has a repeat transversely ofthe fabric, corresponding yarns of each repeat are distributed acrossthe fabric subsequent to passage through a patterning means, thepatterning means controlling the rate of yarn feed, and thus the pileheight, according to the required pattern. Having regard to the factthat the pattern is derived from a difference in pile height of adjacentyarns as distinct from being a pattern in color and is formed at thetufting needles by withdrawal of yarn from previously inserted tufts,the relative longitudinal positions of the individual yarns is of noconsequence.

However, if the pattern is in color and the individual pile yarns aredyed at intervals therealong, the regions of color on adjacent yarnsmust be maintained in their respective relative positions longitudinallyof the yarn if the intended pattern is to appear in the finished fabric.Unfortunately the distribution of corresponding yarns of each patternrepeat transversely of the sheet of pile yarns at the tufting needles,which corresponding yarns are conveniently dyed simultaneously at acommon dyestuff applicator, disturbs the relative positions of theregions of dyestuff on the individual yarns at the needles and thusdisturbs the pattern in the finished product.

The primary object of the present invention is to provide a meanswhereby pattern register as between adjacent yarns can be maintained andeven this during distribution of corresponding yarns widthwise of thefabric to produce a pattern repeat in such fabric.

Thus, according to the present invention, in producing a tufted producthaving a pattern in color transversely thereof and wherein yarns are fedfrom a supply thereof, are dyed at spaced intervals longitudinallythereof and are tufted as a part ofa continuous process, we include thestep of maintaining a constant path length for all yarns between thedyeing section and the tufting machine thereby to maintain a necessarylevel of pattern register between the dyestuff applied to the respectiveindividual yarns throughout the full transverse extent of the product.

The invention also includes apparatus for practicing the methodaforesaid, which apparatus includes a guide means intermediate a dyeingsection and a tufting machine, the said guide means defining a paththerein for each yarn passing therethrough which is of sensibly constantlength independently of the point of entry into and exit from such meansof the yarn, such guide means being adapted to receive yarns from thedyeing section at a relative disposition consistent with the grouping ofsuch yarns for dyeing purposes and to deliver such yarns as a sheet orsheets thereof wherein the yarns are arranged in a relative dispositionconsistent with a pattern or pattern repeat requirement for feeding tothe tufting machine.

The invention will now be described further, by way of example only,with reference to the accompanying drawings illustrating one embodimentthereof and in which:

FIG. l is a diagrammatic representation of the distribution within aguide means of the yarns from a plurality of treatment modules so as toensure a constant path length for all yarns between such modules and atufting machine;

FIG. 2 is a diagrammatic perspective view ofa typical guide means andshows the form taken by the individual tubes which collectively definethe guide means.

Referring now to the drawing, and particularly to FIG. 1 thereof, yarnsII from a plurality of creel modules 12 are fed to a correspondingnumber of dyeing modules 13, dyestuff being applied and fixed at suchmodules and the yarn also being washed and subsequently dried thereat,and from the modules 13, such yarns 11 pass to the tufting machine 14via a guide means 15 adapted to maintain a constant path length for eachyarn between the dyeing modules the tufting machine 14.

Each respective dyeing module 13 will receive those yarns which are tobe similarly treated, for example, the corresponding yarns of eachpattern repeat of the tufted fabric and will be provided with meansarranged in tandem one behind the other to apply the dyestufi to theyarns in any convenient manner, to fix such dyestuff, wash the yarn andto dry same. The guide means 15 disposed between the dyeing modules andthe needles of the tufting machine comprises a multiplicity of tubemembers 15a, one for each yarn, the said tube members all being of equallength thus to ensure a constant path length for all yarns between thedyeing modules and the needles, it being assumed that the path lengthbetween the dyeing modules 13 and the input side 15b of the guide means15 and between the output side of such means and the needles is the samefor all yarns. It has been found that the passage of the yarns throughthe tubes is facilitated if any necessary changes in direction thereofare acute, the radius of curvature at each such change being small.

In the arrangement illustrated in FIG. 1 the yarns are considered to bedivided into eight groups, each group of yarns being intended to besubjected to a different color application, a single yarn from eachgroup being taken to give a full pattern repeat and the remaining yarnsof each group being distributed across the width of the tufting machinethus to give a corresponding number of repeats. If the dyestufi' asapplied to a yarn is so applied at a correct position longitudinallythereof relative to dyestuff applied to other yarns of the same oranother group, then to maintain this relative disposition at the tuftingneedles notwithstanding the distribution of the yarns widthwise of thetufting machine, all of the yarns must have the same actual path lengthbetween the dyeing module and the respective needles, such patternlength being achieved by causing the yarns to pass through the constantlength tube members. While the transverse distribution of the individualyarns at the input side of the guide means is not important, since theyarns are parallel and thus their path lengths between spaced transverseplanes equal, the distribution at the output side is important andshould correspond to the gauge setting of the tufting machine, the yarnspassing to such machine as a sheet or sheets of parallel yarns.

In the particular arrangement illustrated in FIG. 2 yarns are shown asprogressing from modules, not shown, arranged at two different levels,the yarns from the upper module (or group thereof) being passed to tubes20 having their lower ends carried by tube plate 2l while the yarns fromthe lower module (or group thereof) are passed to tubes 22 having theirlower ends carried by tube plate 23. The upper ends of all of the tubes20, 22 are carried by a guide plate 24 from which the yarns pass, witherdirectly or indirectly, to the needles of the tufting machine. The tubesare all of constant length but each tube has its own unique shapedetermined by the entry and exit positions on the plate 21, 23 and theguide plate 24 respectively.

The guide means shown in FIG. 2 is intended to handle a tufted fabrichaving 11 pattern repeats throughout its full width, while each repeatcontains thereby two individual yarns. This arrangement requires that 32groups of yarns, each group being subjected to a respective dyestuffapplication sequence such that all yarns in a given group are alike asregards pattern while the different groups each exhibit a respective andunique pattern characteristic, are provided, and that ll yarns, one foreach pattern repeat, are included within each group. The groups aredivided equally between the upper and lower tube plates 21, 23 andappear on such plates as a corresponding number of inlets groups 25.Within each inlet group 25 are l l inlets 26, each being coupled to arespective tube 20, 22 and each being intended to receive a single yarn.

The invention is not restricted to the exact features of the embodimentdisclosed since alternatives will readily present themselves to oneskilled in the art. Thus, for example, instead of providing a guide tubefor each yarn, a series of spaced l3 and the needles of apertured guidemembers may be provided, the yarns being threaded through said membersin a manner appropriate to give the necessary constant path length.Alternatively the yarns may be guided by eyelets or like means locatedat appropriate relative disposition.

Furthermore, the invention is not limited in its application to thecontext of producing tufted fabrics since it is of equal application inany other context where yarn is passed to a combining machine in sheetform.

What we claim is:

1. In the production of a product having a pattern in color transverselythereof and wherein a plurality of individual yarns is fed from asupply, a color-influencing medium is selectively applied to the yarnsat spaced intervals longitudinally thereof and the yarns from at least apattern in the said product, some of the yarns proceeding along pathshaving at least a part thereof arranged in nonparallel dispositionrelative to those of other yarns at or subsequent to the point of firstcolor-influencing medium application and wherein the yarns areredistributed in the transverse direction thereof between the steps ofmedium application and fonning of the pattern, the step of maintaining aconstant path length for the said yarns between the point of applicationof medium and the point of forming the pattern from the yarns thereby tomaintain a necessary level of pattern register between the mediumapplied to the respective individual yarns throughout the fulltransverse extent of the product.

2. The method as claimed in claim 1 wherein the product is a tuftedproduct and is comprised of the formation of tufts in a backing fabric.

3. Apparatus comprising a guide means for location intermediate acolor-influencing medium applicator and a pattern forming means to guidethe yarns between the aforesaid applicator and an apparatus for forminga pattern from said yarns, the said guide means defining a path thereinfor each yarn passing therethrough which is of sensibly constant lengthindependently of the point of entry into and exit from said guide means,said guide means being adapted to receive yarns from the applicator at arelative disposition consistent with their disposition for applicationpurposes and to deliver said yams as a sheet or sheets thereof whereinthe yarns are arranged in a relative disposition consistent with apattern requirement for feeding to the apparatus for forming thepattern.

4. Apparatus as claimed in claim 3 wherein the guide means is adapted toreceive the said yarns in a relative disposition consistent with thegrouping of like yarns for application purposes and to effect aredistribution of the yarns in the transverse direction thereofconsistent with a pattern repeat requirement.

5. Apparatus as claimed in claim 3 wherein the guide means includes aplurality of guide tubes, one for each yarn, extending between spacedfeed and delivery points, the said tubes all being ofa like length andhaving bends therein determined by the relative disposition of the saidpoints.

6. Apparatus as claimed in claim 5 wherein the guide tubes all havecorresponding bends therein.

7. Apparatus as claimed in claim 6 wherein the tubes are grouped todefine a plurality of inlet levels, each such inlet level having acommon outlet level.

1. In the production of a product having a pattern in color transverselythereof and wherein a plurality of individual yarns is fed from asupply, a color-influencing medium is selectively applied to the yarnsat spaced intervals longitudinally thereof and the yarns from at least apattern in the said product, some of the yarns proceeding along pathshaving at least a part thereof arranged in nonparallel dispositionrelative to those of other yarns at or subsequent to the point of firstcolorinfluencing medium application and wherein the yarns areredistributed in the transverse direction thereof between the steps ofmedium application and forming of the pattern, the step of maintaining aconstant path length for the said yarns between the point of applicationof medium and the point of forming the pattern from the yarns thereby tomaintain a necessary level of pattern register between the mediumapplied to the respective individual yarns throughout the fulltransverse extent of the product.
 2. The method as claimed in claim 1wherein the product is a tufted product and is comprised of theformation of tufts in a backing fabric.
 3. Apparatus comprising a guidemeans for location intermediate a color-influencing medium applicatorand a pattern forming means to guide the yarns between the aforesaidapplicator and an apparatus for forming a pattern from said yarns, thesaid guide means defining a path therein for each yarn passingtherethrough which is of sensibly constant length indepEndently of thepoint of entry into and exit from said guide means, said guide meansbeing adapted to receive yarns from the applicator at a relativedisposition consistent with their disposition for application purposesand to deliver said yarns as a sheet or sheets thereof wherein the yarnsare arranged in a relative disposition consistent with a patternrequirement for feeding to the apparatus for forming the pattern. 4.Apparatus as claimed in claim 3 wherein the guide means is adapted toreceive the said yarns in a relative disposition consistent with thegrouping of like yarns for application purposes and to effect aredistribution of the yarns in the transverse direction thereofconsistent with a pattern repeat requirement.
 5. Apparatus as claimed inclaim 3 wherein the guide means includes a plurality of guide tubes, onefor each yarn, extending between spaced feed and delivery points, thesaid tubes all being of a like length and having bends thereindetermined by the relative disposition of the said points.
 6. Apparatusas claimed in claim 5 wherein the guide tubes all have correspondingbends therein.
 7. Apparatus as claimed in claim 6 wherein the tubes aregrouped to define a plurality of inlet levels, each such inlet levelhaving a common outlet level.